Process for internally loading liquids onto carriers and achieving dry liquid concentrates

ABSTRACT

Process for internally loading liquids onto carriers and achieving time-release dry liquid concentrate. The resulting time-release dry liquid concentrates having a variety of applications, including animal attractants and repellants, down hole chemicals, flavors and fragrances of food and beverages, treatment of contaminants, fertilizers, vitamins.

CROSS REFERENCES TO RELATED APPLICATION

This application claims the benefit of and priority to U.S. Provisional Application Ser. No. 62/458,629, filed Feb. 14, 2017, and entitled Internally Loading Liquids onto Scoria, Perlite, Pumice, Aerogels, Activated Alumina, Fullerenes, Graphite, Molybdenum, Magnetite, Vermiculite, Activated Charcoal, Cellulose, Superabsorbent Polymers (SAPs), Chitin and other Biopolymers, and Superabsorbent Polymers (SAPs), Chitin and other Biopolymers, and Precipitated Silica to Achieve a Dry Liquid Concentrate (DLC) or Slurry, which is incorporated by reference herein.

FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

BACKGROUND OF THE INVENTION 1. Field of the Invention

The present invention relates to the chemical manufacture of solids loaded with liquids, and to methods of making and using such solids loaded with liquids. In another aspect, the present invention relates to the chemical manufacture of solids loaded with liquids that are designed for time release, and to methods of making and using such homogenous mixtures.

2. Description of the Related Art

Time release chemicals are often sought after for the benefits that come with releasing a chemical over time rather than all at once. By example, time-release chemicals often release more efficiently. They often release the desired chemical—which may be quite expensive or limited—more judiciously. And of course, time release chemicals release chemicals either gradually or delayed to a time that is more desirable than instant or immediate release.

In pharmaceuticals, time-release drugs are formulated so that the active ingredient is embedded in a matrix of insoluble substance(s) such that the dissolving drug must find its way out through the holes. In some formulations, the drug dissolves into the matrix, and the matrix physically swells to form a gel, allowing the drug to exit through the gel's outer surface.

Controlled-release (CRF) and slow-release (SRF) fertilizers belong to the larger group of enhanced-efficiency fertilizers, which also include nitrogen stabilizers, nitrification inhibitors, urease inhibitors, and stabilized fertilizers. Controlled-release fertilizers are generally coated products. Slow-release fertilizers are noncoated products in which the nutrient release is uncontrolled but slow. These are mainly urea-aldehyde reaction products but also other slowly soluble products such as fertilizer spikes and ion exchange resin fertilizers. Whereas the bulk of the market belongs to the stabilizers and inhibitors categories, CRFs and SRFs are used at much smaller volumes and therefore might be considered specialties.

Though controlled- and slow-release fertilizers have been shown to have efficacy, their use is relatively limited as they are much more expensive than the commercial fertilizers in the market. Sulfur-coated urea is the least expensive slow-release fertilizer. Other controlled or slow-release fertilizers can cost anywhere between 2.4 and 10 times as much as conventional fertilizers. For this reason they are used primarily in niche markets like golf courses, landscaping purposes, and greenhouses.

In spite of the advancements in the art of liquid carriers, there is still the need for improved chemical manufacture of solids loaded with liquids that are designed for time release, and methods of making and using same.

BRIEF SUMMARY OF THE INVENTION

It is an object of the present invention to provide for improved time-release dry liquid carriers, and methods of making and using same. Such carriers coming from a group of solids having similar physical characteristics relating to their porosity and permeability such that each possess a large internal carrying capacity.

These and other embodiments of the present invention will become apparent to those of skill in the art upon review of this specification, including its drawings and claims.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 is a flowchart illustrating the steps in making a time-release dry liquid concentrate described herein.

FIG. 2 is a flowchart illustrating the steps in making a blend of two or more time-release dry liquid concentrates described herein.

DEFINITIONS

The following definitions are provided in order to aid those skilled in the art in understanding the detailed description of the present invention.

In embodiments described and disclosed herein, the use of the term “introducing” includes pumping, injecting, pouring, releasing, displacing, spotting, circulating, or otherwise placing a fluid or material within a well, wellbore, or subterranean formation using any suitable manner known in the art. Similarly, as used herein, the terms “combining”, “contacting”, and “applying” include any known suitable methods for admixing, exposing, or otherwise causing two or more materials, compounds, or components to come together in a manner sufficient to cause at least partial reaction or other interaction to occur between the materials, compounds, or components.

The term “solid carrier”, as used herein, means and refers generally to members of a group of solids having similar physical characteristics relating to their porosity and permeability such that each possess a large internal carrying capacity. These solid carriers consist of scoria, perlite, pumice, aerogels, activated alumina, fullerenes, graphite, molybdenum, magnetite, vermiculite, activated charcoal, cellulose, superabsorbent polymers (SAPS), chitin and other biopolymers, and superabsorbent polymers (SAPS), chitin and other biopolymers, and precipitated silica.

DETAILED DESCRIPTION OF THE INVENTION

One or more illustrative embodiments incorporating the invention disclosed herein are presented below. Not all features of an actual implementation are described or shown in this application for the sake of clarity. It is understood that in the development of an actual embodiment incorporating the present invention, numerous implementation-specific decisions must be made to achieve the developer's goals, such as compliance with system-related, business-related, government-related and other constraints, which vary by implementation and from time to time. While a developer's efforts might be complex and time-consuming, such efforts would be, nevertheless, a routine undertaking for those of ordinary skill in the art having benefit of this disclosure.

These embodiments are directed toward the loading of liquids, solids dissolved in liquids (solutions), suspensions, solids heated to reduce viscosity onto Solid Carriers to achieve a dry liquid concentrate (DLC).

These embodiments can include, but not be limited to, animal attractants or repellants, oil treatment and production chemicals, flavors, such in coffee and tea packets, fragrances, biological treatment and remediation systems, bio-reactor substrates, cleaning chemicals, pesticides, herbicides, fungicides, vitamins, fertilizers, or any combination of the above or any material benefiting from a DLC.

Composition

The present invention relates to the making, use and composition of time-release Dry Liquid Concentrates (DLC). In one embodiment of the present invention, liquid animal attractants (e.g. Pheromones and/or flavors or fragrances) or repellants are loaded onto solid carriers, such as scoria, Perlite, pumice, aerogels, activated alumina, fullerenes, graphite, molybdenum, magnetite, vermiculite, activated charcoal, Cellulose, Superabsorbent Polymers (SAPs), Chitin and other Biopolymers, and or precipitated silica (collectively, “Solid Carriers”). These internally absorbent carriers can act to extend the shelf life of normally temperature, oxygen and light sensitive agents as well as allow time-release action and decrease movement in the soil.

In other embodiments of the present invention, down hole chemicals are loaded onto Solid Carriers and introduced to the formation via being mixed with propellants (e.g., explosives) or other means. In downstream gas and oil well production chemicals are loaded onto Solid Carriers and introduced into the stream by means of a bed placed inline. The carrier substrates can impart time release properties, avoid undesirable side reactions prior to use, improve shelf life and increase distribution of the treatment system.

Additionally, activated carbon may be calcined to increase propellant strength. The particle size of the activated carbon may be sized to incorporate well with the other propellants or proppants. Perlite and pumice have a low density and allows for DLC's that can float on water. Scoria possesses a high density and can be used for heavier than water applications. Scoria and pumice possess hard structures that may allow for higher crush applications. Precipitated silica and activated carbon may be over-saturated (greater than 90% loading) with liquids to form slurries.

In another embodiment of the present invention, flavors and fragrances loaded onto activated carbon (or other Solid Carriers) may be blended with beverage components that are filtered via membrane, such as tea bags, coffee filters and cartridges (e.g., Keurig®) system or a multi-component system, to avoid premature reaction between the flavors/fragrances with the tea leaves, coffee granules or other beverage components.

In another embodiment of the present invention, fragrances that are incompatible with solid substrates, such as potpourri, may be loaded onto Solid Carriers to improve compatibility with the solid, increase shelf life and act as a time release system.

In another embodiment of the present invention, microbial and enzymatic systems are loaded onto Solid Carriers. The surface area of the carriers enhances microbial growth. Scoria's density may allow the system to sink to the bottom of the water. Pumice and Perlite allow the carrier to float on water, the pumice being nonfriable and the Perlite is friable (i.e., crumbly). The carrier's particle size may be selected to lock into the soil substrate or facilitate application via rotary spreader. Proper carrier substrate formulation may allow oil and stain remediation of concrete or gravel, such as found at fueling stations, fuel transfer and oil change facilities, railway beds and yards, convenience stores, etc. Such systems may be used in the treatment of hydrocarbons, heavy metals, radioactivity, salt or other contaminants.

In another embodiment of the present invention, microbial and enzymatic systems are loaded onto Solid Carriers and act as a microbial delivery system in a bio-reactor tank. The surface area of the carrier enhances growth of the microbes and in bed form improves contact with the treated material, such as contaminated water.

In another embodiment of the present invention, cleaning chemicals, such as surfactants, may be loaded onto Solid Carriers for delivery on hydrocarbon contaminated substrates.

In another embodiment of the present invention, fertilizers, pesticides, herbicides and fungicides may benefit from Solid Carriers as the UV resistance, soil retention, bulking/dilution and mechanical delivery of the active ingredients may be improved.

In another embodiment of the present invention, vitamins may be delivered more efficiently in aquaculture applications, as the Solid Carriers can improve UV, temperature and oxygen resistance of the vitamins, allow for time-release of the nutrients into the water, decrease the loss due to dilution in open water systems and help clean the water.

Method of Making

FIG. 1 illustrates the steps in making the time-release dry liquid concentrate (DLC) described herein. In this embodiment, a first step 102 is placing a solid carrier into a mixing device, such as a barrel mixer. The second step 104 is placing a liquid into the mixing device. The third step 106 is mixing the contents of the mixing device. The fourth step 108 is drying the contents of the mixing device. In this particular embodiment, drying may be carried out in an oven.

The fifth step 110 (optional) is measuring the moisture content of the mixture. The moisture content may be measured in this step by one or more means including: comparing the weight of the mixture versus the anticipate weight; chilled mirrors; spectroscopy; etc. Step 108 and step 110 may be repeated until desired moisture content is achieved. The sixth step 112 is concluding the process once the desired moisture content is achieved.

The next several paragraphs are intended to offer alternative embodiments or even further explanation of the steps 102-112 described above.

One of ordinary skill in the art will recognize that any number of mixing devices would be appropriate for executing the process described herein. Moreover, in certain embodiments, mixing must be carried out in a pressure vessel such that increase pressure and temperature are exerted on the contents of the mixture so as to achieve sufficient loading.

As an alternative, or in combination to, use of an oven in step 108, this process may be carried out with other drying techniques, such as air drying, sun drying, or other processes known in the art.

FIG. 2 illustrates the steps in making a blend of two or more time-release dry liquid concentrates described herein. In this embodiment, a first step 202 is placing a solid carrier into a mixing device, such as a barrel mixer. The second step 204 is placing a liquid into the mixing device. The third step 206 is mixing the contents of the mixing device. The fourth step 208 is drying the contents of the mixing device. In this particular embodiment, drying may be carried out in an oven.

The fifth step 210 (optional) is measuring the moisture content of the mixture. The moisture content may be measured in this step by one or more means including: comparing the weight of the mixture versus the anticipate weight; chilled mirrors; spectroscopy; etc. Steps 208 and 210 may be repeated until desired moisture content is achieved. The sixth step 212 is stopping the process once the desired moisture content is achieved. After sixth step 212, the mixture is a time-release dry liquid concentrate comprising a solid carrier and a liquid loaded thereon. The benefits of the DSL are described herein and in various examples.

The seventh step 214 is the blending of the mixture (i.e., DLC) resulting from steps 202 through step 212 with a second mixture (e.g., DLC). In certain situations, the user may wish to combine one DLC with a DLC comprising a different solid and/or a different liquid. Step 214 carries out this objective.

While compositions and methods are described in terms of “comprising” various components or steps, the compositions and methods can also “consist essentially of” or “consist of” the various components and steps.

The following examples are included to demonstrate preferred embodiments of the invention. It should be appreciated by those of skill in the art that the techniques disclosed in the examples which follow represent techniques discovered by the inventors to function well in the practice of the invention, and thus can be considered to constitute preferred modes for its practice. However, those of skill in the art should, in light of the present disclosure, appreciate that many changes can be made in the specific embodiments which are disclosed and still obtain a like or similar result without departing from the scope of the invention.

EXAMPLES Example 1

A 52% bacterial DLC is produced by loading 12 grams of bacteria solution onto 11 grams of activated charcoal. In this example, a bacterial solution—such as AquaVitro Remediation Bacteria, designed to remediate organic waste such as food, sludge and detritus—is mixed with the activated carbon. In this example embodiment, the solid DLC formulation of the bacteria allows its waste remediation properties to stay in place and time release into a treated matrix such as soil, proppants or other solid substrates.

Example 2

A 52% bacterial DLC is produced by loading 14 grams of bacteria solution onto 13 grams of activated charcoal. In this example, the bacterial solution contains anaerobic and aerobic facultative and nitrifying and denitrifying bacteria is mixed with activated carbon. In this example embodiment, the solid DLC formulation of the bacteria allows its waste remediation properties to stay in place and time release into the treated matrix such as soil, proppants or other solid substrates.

Example 3

A 56% bacterial DLC is produced by loading 14 grams of bacteria solution onto 11 grams of activated charcoal. In this example, the bacterial solution—such as AP StressZyme (Mars)—is designed to remove sludge from aquatic surfaces, and is mixed activated carbon. In this example, the solid DLC formulation of the bacteria allows its waste remediation properties to stay in place and time release into the treated matrix such as soil, filter media, gravel or other solid substrates.

Example 4

A 52% bacterial DLC is produced by loading 13 grams of the bacteria solution onto 12 grams of activated charcoal. In this example, the bacterial solution—such as Bio-Spira (Marineland)—contains nitrifiers designed to remove ammonia and nitrite from aquatic environments, and is mixed with activated carbon. In this example, the solid DLC formulation of the bacteria allows its waste remediation properties to stay in place and time release into the treated matrix such as soil, filter media, gravel or other solid substrates.

Example 5

A 48% DLC of hog attractant is produced by loading 9.1 grams of a hog attractant onto 10.0 grams of activated charcoal. In this example, the hog attractant—such as Black Gold hog attractant from Wild Boar USA—is mixed with the activated carbon. In this example, the solid DLC formulation of the liquid hog attractant allows the active ingredient to lock into place and time release into a soil matrix.

Example 6

A 38% DLC of thymol is produced by loading 6.2 grams of thymol onto 10.0 grams of activated charcoal. In this example, the solid DLC formulation of the thymol allows its germicidal properties liquid attractant allows the active ingredient to stay in place and time release into the treated matrix such as soil, proppants or other solid substrates.

Example 7

A 32% DLC of peppermint oil is produced by loading 4.8 grams of the active ingredient onto 10.0 grams of activated charcoal. In this example, the solid DLC formulation of the peppermint oil allows its animal repellent properties to lock in place and time release in the soil matrix or other substrate where it is applied.

Example 8

A 33% DLC of eucalyptol is produced by loading 5.0 grams of the active ingredient onto 10.0 grams of activated charcoal. In this example, the solid DLC formulation of the eucalyptol allows its animal repellent properties to lock in place and time release in the soil matrix or other substrate where it is applied.

Example 9

A 61% DLC of 10% surfactant solution is produced by loading 17 grams of a 10% surfactant solution onto 11 grams of activated charcoal. The surfactant used is made by mixing 11 grams of a detergent or pretreating material—such as Wisk Concentrate by Sun Products Corporation—in 93 grams of water. In this example, the surfactant solution is mixed with the activated carbon. This surfactant DLC may be used as a cleaner and hydrocarbon remediation product. The solid DLC allows the surfactant to stay in place and time release into the treated matrix such as soil, proppants or other solid substrates.

Example 10

A 61.4% wet-weight DLC of tire pyrolysis oil is mixed with Perlite powder of up to ½-inch particles. Tire pyrolysis oil can be used to remove paraffinic compounds in down-hole applications. The density of the Perlite DLC allows the product to float on water. The high friability of the Perlite allows for the DLC to be readily crushed to rapidly release the carried liquid.

Example 11

An 18.7% wet-weight DLC of tire pyrolysis oil is mixed with scoria granules up to ⅛ inches in diameter. As noted above, tire pyrolysis oil can be used to remove paraffinic compounds in down-hole applications. The density of the scoria DLC allows the product to sink in water. The low friability of the scoria allows for the DLC to resist crushing under pressure and abrasion.

Example 12

A 20.4% wet-weight DLC of tire pyrolysis oil is mixed with pumice granules ranging from ⅛ inch to ½ inch in diameter. The density of the pumice DLC allows the product to float on water. The low friability of the pumice allows for the DLC to resist crushing under pressure and abrasion.

Example 13

A 74.2% wet-weight (57.5% dry weight) DLC of microbes—such as those offered by First Generation Microbials, LLC—is mixed with Perlite powder of up to ½-inch particles. The density of the Perlite DLC allows the mixture to float on water. The high friability of the Perlite allows for the DLC to be readily crushed to rapidly release the carried liquid.

Example 14

A 10.3% dry-weight DLC of microbes is mixed with scoria granules up to ⅛ inches in diameter. The density of the scoria DLC allows the mixture to sink in water. The low friability of the scoria allows for the DLC to resist crushing under pressure and abrasion.

Example 15

A 16.2% dry-weight DLC of microbes is produced on pumice with granule sizes ranging from ⅛ to ½ inches in diameter. The density of the pumice DLC allows the mixture to float on water. The low friability of the pumice allows for the DLC to resist crushing under pressure and abrasion.

Example 16

An 81.3% dry-weight DLC of microbes is produced on vermiculite with granule sizes ranging from 1/16 to ½ inches in diameter.

Example 17

A 47.8% wet-weight DLC of microbes is produced on ⅛-inch diameter activated carbon.

Example 18

A 59.0% wet-weight DLC of microbes is mixed with diatomaceous earth powder.

One of ordinary skill in the art will recognize that the eighteen (18) examples above are merely examples and not an exhaustive list of combinations (by weight or type) for the invention to be executed. For instance, other combinations by weight could be implemented. Similarly, other combinations of identified solid carriers could be used with the liquids identified herein.

Unless otherwise indicated, all numbers expressing quantities of ingredients, properties such as molecular weight, reaction conditions, and so forth used in the present specification and associated claims are to be understood as being modified in all instances by the term “about”. Accordingly, unless indicated to the contrary, the numerical parameters set forth in the following specification and attached claims are approximations that may vary depending upon the desired properties sought to be obtained by the present invention. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claim, each numerical parameter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques.

Finally, all articles, books, information, journals, magazines, materials, newsletters, newsletters, online materials, patent applications, patent publications, periodicals, publications, texts, and treatises, and/or any other type of publication, cited in this application are herein incorporated by reference in their entirety as if each individual reference was specifically and individually set forth herein. It should be understood that incorporated information is as much a part of the application as filed as if the information was repeated in the application, and should be treated as part of the text of the application as filed.

The present invention is described above in terms of a preferred illustrative embodiment in which a specifically described diverting agent and methods are described. Those skilled in the art will recognize that alternative constructions of such an apparatus, system, and method can be used in carrying out the present invention. Other aspects, features, and advantages of the present invention may be obtained from a study of this disclosure and the drawings, along with the appended claims. 

1. A time-release dry liquid concentrate, comprising: a solid carrier selected from the group consisting of scoria, perlite, pumice, aerogels, activated alumina, fullerenes, graphite, molybdenum, magnetite, vermiculite, activated charcoal, cellulose, superabsorbent polymers, chitin, and precipitated silica; and a liquid mixed with the solid carrier.
 2. The time-release dry liquid concentrate of claim 1 wherein the liquid is a bacterial solution.
 3. The time-release dry liquid concentrate of claim 2 wherein the bacterial solution is 52% of the dry liquid concentrate by weight.
 4. The time-release dry liquid concentrate of claim 3 wherein the solid carrier is activated charcoal.
 5. A method for making a dry liquid concentrate comprising: placing a solid carrier selected from the group consisting of scoria, perlite, pumice, aerogels, activated alumina, fullerenes, graphite, molybdenum, magnetite, vermiculite, activated charcoal, cellulose, superabsorbent polymers, chitin, and precipitated silica into a mixing device; placing liquid into the mixing device; mixing the solid and the liquid in the mixing device; and drying the mixture.
 6. The method of claim 5 wherein the steps are carried out a first time to form a first mixture and comprising the following additional steps: placing a solid carrier selected from the group consisting of scoria, perlite, pumice, aerogels, activated alumina, fullerenes, graphite, molybdenum, magnetite, vermiculite, activated charcoal, cellulose, superabsorbent polymers, chitin, and precipitated silica into a mixing device; placing liquid into the mixing device; mixing the solid and the liquid in the mixing device to form a second mixture; and blending the first mixture with the second mixture. 